Method for manufacturing a biocompatible cathode slurry for use in biocompatible batteries for a contact lens

Abstract

Methods and apparatus to form biocompatible energization elements are described. In some examples, the methods and apparatus to form the biocompatible energization elements involve forming cavities comprising active cathode chemistry. The active elements of the cathode and anode are sealed with a biocompatible material. In some examples, a field of use for the methods and apparatus may include any biocompatible device or product that requires energization elements.

What is claimed is: 
     
         1 . A method for manufacturing a biocompatible battery for use in a contact lens comprising the steps of:
 mixing one or more of a liquid phase pre-mixture with one or more of a solid phase pre-mixture into a cathode slurry mixture;   filtering the cathode slurry mixture, wherein the filtering removes particles from the cathode slurry which may cause insufficient filling of a laminated core of the biocompatible battery;   distributing the cathode slurry mixture into a biocompatible cathode for use in a biocompatible battery, wherein the filtering occurs before the distributing of the cathode slurry;   sealing the laminated core for biocompatibility; and   inserting the biocompatible battery in a contact lens, wherein the filtering of the cathode slurry mixture supports forming the biocompatible battery into a small enough form to fit into the contact lens.   
     
     
         2 . The method of  claim 1  wherein the filtering occurs in a recirculating loop of a cathode slurry distribution system. 
     
     
         3 . The method of  claim 2  further comprising storing and recirculating the cathode slurry mixture after filtering the cathode slurry mixture. 
     
     
         4 . The method of  claim 2  further comprising drying the cathode slurry mixture. 
     
     
         5 . The method of  claim 2  wherein the liquid phase pre-mixture comprises one or more reagents wherein at least one reagent is a liquid phase reagent. 
     
     
         6 . The method of  claim 5  further comprising filtering the liquid phase reagents. 
     
     
         7 . The method of  claim 5  wherein one liquid phase reagent comprises a solvent. 
     
     
         8 . The method of  claim 2  wherein the solid phase pre-mixture comprises one or more solid phase reagents. 
     
     
         9 . The method of  claim 8  further comprising sieving the solid phase reagents to a uniform particle size. 
     
     
         10 . The method of  claim 8  wherein the solid phase reagent comprises a jet milled electrolytic manganese dioxide. 
     
     
         11 . The method of  claim 8  wherein one solid phase pre-mixture comprises a transition metal oxide. 
     
     
         12 . The method of  claim 11  wherein the transition metal oxide comprises manganese dioxide. 
     
     
         13 . The method of  claim 8  wherein one solid phase reagent comprises a carbon allotrope. 
     
     
         14 . The method of  claim 13  wherein the carbon allotrope comprises graphite. 
     
     
         15 . The method of  claim 14  wherein the graphite comprises carbon black. 
     
     
         16 . The method of  claim 5  wherein the liquid phase pre-mixture comprises a hydrophobic binder. 
     
     
         17 . The method of  claim 16  wherein the hydrophobic binder comprises polyisobutylene (PIB). 
     
     
         18 . The method of  claim 16  wherein the hydrophobic binder comprises a fluorocarbon solid. 
     
     
         19 . The method of  claim 18  wherein the fluorocarbon solid comprises polytetrafluoroethylene (PTFE). 
     
     
         20 . The method of  claim 1  further comprising:
 obtaining a laminar structure wherein the laminar structure has a volume removed to form a cavity, wherein the laminar structure comprises a first anode collector layer laminated to a first laminar construct core, wherein the first laminar construct core had the volume removed from its body before it was laminated to the first anode collector layer, and wherein the laminar structure comprises an electroplated anode film and a deposited separator film thereupon within the cavity, wherein the deposited separator film is deposited as a solution comprising a solvent which evaporates to form a separator film; and 
 checking a quality of the solid phase pre-mixture and the liquid phase pre-mixture, wherein the quality that is checked is the particle size distribution.